Apparatus and methods for adhesion

ABSTRACT

A material engagement element sheet formed from a sheet material ( 10 ) incorporates a pattern of material engagement element slots ( 14 ), each slot containing an array of material engagement elements ( 20 ) which have a tapered distal section ( 30 ), a flange section ( 34 ) and a proximal section ( 32 ) which is attached to an edge of the slots in the sheet material. The material engagement element sheet material may be a single layer of shape memory material, or the sheet material may be a composite of different layers some of which may include pre-strained shape memory materials with distinguishable activation parameters. The material engagement element slot configuration allows for the simultaneous processing of the material engagement elements. The material engagement elements may be processed such that they are in a state that is substantially perpendicular to the surface of the material engagement element sheet. The configuration of the flexible base material and the pattern of the material engagement element slots may be used in order to manufacture various material engagement element devices including a material engagement element pad device ( 166 ), a cylindrical material engagement element device ( 104, 105 ), and a spherical material engagement element device ( 152 ).

RELATED APPLICATIONS

This patent application is a continuation of U.S. patent applicationSer. No. 15/156,893 which is a continuation of U.S. patent applicationSer. No. 14/240,668 which is a US national filing of PCT applicationserial no. PCT/US12/52307 filed on Aug. 24, 2012 claiming priority ofU.S. Provisional Patent Application Ser. No. 61/527,560 filed on Aug.25, 2011, and is copending with U.S. patent application Ser. No.15/601,187 filed on May 22, 2017 having a common assignee with thepresent application, the disclosures of which are incorporated herein byreference.

SUMMARY

A material engagement element sheet formed from a sheet materialincorporates a pattern of material engagement element slots, each slotcontaining an array of material engagement elements which have a tapereddistal section, a flange section and a proximal section which isattached to an edge of the slots in the sheet material. The materialengagement element sheet material may be a single layer of shape memorymaterial, or the sheet material may be a composite of different layerssome of which may include pre-strained shape memory materials withdistinguishable activation parameters. The material engagement elementslot configuration allows for the simultaneous processing of thematerial engagement elements. The material engagement elements may beprocessed such that they are in a state that is substantiallyperpendicular to the surface of the material engagement element sheet.The distal sections of the material engagement elements may then beinserted into a temporary stabilizing material; the temporarystabilizing material prevents the premature deployment of the materialengagement elements and maintains the position of each tissue engagementrelative to the surrounding tissue engagement elements. The proximalsections of the tissue engagement elements may then be suitablyencapsulated in a flexible base material. The configuration of theflexible base material and the pattern of the material engagementelement slots may be used in order to manufacture various materialengagement element devices including a material engagement element paddevice, a cylindrical material engagement element device, and aspherical material engagement element device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a material engagement element sheetembodiment being produced from sheet material.

FIG. 1B is a perspective view of a completed material engagement elementsheet embodiment.

FIG. 1C is an enlarged view of a portion of the material engagementelement sheet of FIG. 1B showing the material engagement elements andthe material engagement element slots.

FIG. 1D shows the profile of a material engagement element embodimentthat is attached to a material engagement element sheet.

FIG. 2A shows a perspective view of a bottom radius fixture.

FIG. 2B shows a perspective view of the bottom radius fixture of FIG. 2Awith a material engagement element sheet loaded onto it.

FIG. 2C is a perspective view of a top radius fixture which is shown insection view, the bottom radius fixture of FIG. 2A, and the engagementelement patterned sheet.

FIGS. 2D-2G show a section of the top radius fixture and bottom radiusfixture being forced together in order to shape an engagement element.

FIG. 2I is an enlarged view of a portion of FIG. 2C.

FIG. 2J is a perspective view of the material engagement element sheetof FIG. 1B with the elements in an engagement state.

FIGS. 3A-3D depict the material engagement element sheet with theelements in an engagement state of FIG. 2J being transformed into amaterial engagement element sheet with elements in a flat state via anapplied force to two flat plate fixtures.

FIG. 4A is a perspective view of a bottom perpendicular fixture.

FIG. 4B is a perspective view of the bottom perpendicular fixture ofFIG. 4A with the material engagement element sheet placed over it.

FIG. 4C is a perspective view of the bottom perpendicular fixture whichis shown in section view, a top perpendicular fixture, and the materialengagement element sheet with the fixtures engaged and the elements in aperpendicular state.

FIGS. 4D and 4E are cut away views of the top and bottom perpendicularfixtures forced together in order to shape an engagement element into aperpendicular state.

FIG. 4F is an enlarged view of FIG. 4C.

FIG. 4G is a perspective view of the material engagement element sheetwith the elements in a perpendicular state.

FIG. 5A is a perspective view of a bottom mold fixture whichincorporates a temporary stabilizing material mold cavity.

FIG. 5B is a perspective view of the bottom mold fixture of FIG. 5A withthe temporary stabilizing material mold cavity partially filled withtemporary stabilizing material.

FIG. 5C is a view of the temporary stabilizing material with the bottommold fixture not shown for clarity of illustration.

FIG. 5D shows the bottom mold fixture, and the material engagementelement sheet with the elements in a perpendicular state partiallydeployed into the temporary stabilizing material.

FIG. 5E shows the assembly of FIG. 5D with the bottom mold fixturehidden for clarity of illustration.

FIG. 5F is an elevation view of the material engagement element sheetwith the elements in a perpendicular state, the temporary stabilizingmaterial which surrounds the material engagement element distal ends,and the barrier material.

FIG. 5G shows FIG. 5E with the addition of top mold fixture which isshown in a section view.

FIG. 5H shows the assembly of FIG. 5G with a flexible base materialadded to a mold cavity in the top mold fixture which is shown in sectionview.

FIG. 5I shows the assembly of FIG. 5H with the top and bottom moldfixtures hidden for clarity of illustration.

FIG. 5J is an elevation view of the material engagement element sheetwith the elements in a perpendicular state, the temporary stabilizingmaterial, the flexible base material, and the barrier material.

FIG. 6A illustrates the assembly of FIG. 5J with the excess sheetmaterial trimmed after the assembly has been removed from the top moldfixture and the bottom mold fixture.

FIGS. 6B and 6C illustrate the removal of the temporary stabilizingmaterial from the material engagement element pad assembly.

FIG. 6D is a perspective view of an engagement pad assembly ready fordeployment.

FIG. 7A is a perspective view of an assembly of a material engagementelement sheet with the elements in a perpendicular state partiallydeployed into a temporary stabilizing material.

FIG. 7B is an enlarged view of the assembly of FIG. 7A.

FIG. 7C depicts a cylindrical mandrel and the assembly of FIGS. 7A and7B.

FIG. 7D illustrates the assembly of FIGS. 7A and 7B wrapped around thecylindrical mandrel.

FIG. 7E is the assembly shown in FIG. 7D with the excess sheet materialtrimmed off of the material engagement element sheet with elements inperpendicular state.

FIG. 7F is a cross section view of the assembly of FIG. 7E showing thematerial engagement element distal tips pointing inward toward the axisof the cylindrical mandrel.

FIG. 7G shows a bottom cylindrical mold.

FIG. 7H shows the assembly of FIG. 7E loaded into the bottom cylindricalmold of FIG. 7G.

FIG. 7I illustrates the assembly of FIG. 7H with the addition of a topcylindrical mold which is shown in section view and which is engagedwith the bottom cylindrical mold.

FIG. 7J shows the assembly of FIG. 7I with the addition of a flexiblebase material added to the top cylindrical mold cavity and the bottomcylindrical mold cavity.

FIG. 7K illustrates an assembly of the temporary stabilizing material,the flexible base material, and the cylindrical mandrel after theassembly has been removed top cylindrical mold and the bottomcylindrical mold.

FIGS. 7L and 7M depict the removal and inversion of the temporarystabilizing material and flexible base material from the cylindricalmandrel.

FIG. 7N shows the inverted flexible base material and temporarystabilizing material assembly.

FIG. 7O is a cut away view of the assembly of FIG. 7N showing thematerial engagement element distal ends pointing away from the centralaxis of the assembly.

FIG. 7P is the cylindrical material engagement element device after thetemporary stabilizing material has been removed.

FIG. 7Q is another embodiment of the cylindrical material engagementelement device wherein the flexible base material is configured as aballoon.

FIG. 8A shows a spherical gore profile with numerical values and theprofile of a spherical material engagement element slot.

FIG. 8B shows a spherical material engagement element sheet formed with8 gore profiles.

FIG. 8C is an enlarged view of FIG. 8B, showing material engagementelements and spherical material engagement element slots.

FIG. 8D shows a spherical bottom radius fixture.

FIG. 8E shows the spherical bottom radius fixture of FIG. 8D with thespherical material engagement element sheet of FIG. 8B placed on it.

FIG. 8F illustrates the assembly of FIG. 8E with the addition of aspherical top radius fixture which is shown in section view and which isengaged with the spherical bottom radius fixture.

FIG. 8G is an enlarged view of FIG. 8F showing the material engagementelements configured in the engagement state.

FIG. 8H shows the spherical material engagement element sheet with theelements in the engagement state.

FIGS. 8I-8J depict the flattening of the spherical material engagementelement sheet with the elements in the engagement state.

FIG. 8L shows a spherical bottom perpendicular fixture.

FIG. 8M shows the spherical material engagement element sheet on placeover the spherical bottom perpendicular fixture of FIG. 8L.

FIG. 8N illustrates the assembly of FIG. 8M with the addition of aspherical top perpendicular fixture which is shown in section view andwhich is engaged with the spherical bottom perpendicular fixture.

FIG. 8O is an enlarged view of FIG. 8N.

FIG. 9A shows a spherical flat mold fixture.

FIG. 9B shows the spherical flat mold fixture of FIG. 9A partiallyfilled with a temporary stabilizing material.

FIG. 9C shows the assembly of FIG. 9B with a spherical materialengagement element sheet with the elements in the perpendicular statedeployed into the temporary stabilizing material.

FIG. 9D is an enlarged view of FIG. 9C showing the material engagementelements in the perpendicular state partially deployed into thetemporary stabilizing material.

FIGS. 9E and 9F show the assembly comprised of the spherical materialengagement element sheet with the elements in the perpendicular stateand the temporary stabilizing material removed from the spherical flatmold fixture.

FIG. 9G shows the assembly of FIGS. 9E and 9F with the excess sheetmaterial trimmed.

FIG. 9H shows a spherical mold.

FIG. 9I shows the assembly of FIG. 9G and an assembly similar to itbeing applied to the surface of the spherical mold.

FIG. 9J shows the assembly of FIG. 9G and an assembly similar to itafter the application to the spherical mold.

FIG. 9K is an enlarged view of FIG. 9J.

FIG. 9L shows a spherical bottom mold fixture.

FIG. 9M shows the assembly from FIG. 9J inserted into the sphericalbottom mold fixture.

FIG. 9N illustrates the assembly of FIG. 9M with the addition of aspherical top mold fixture which is shown in section view and which isengaged with the spherical bottom mold fixture.

FIG. 9O shows the assembly of FIG. 9N with flexible base material moldedinto the bottom spherical flexible base material mold cavity and topspherical flexible base material mold cavity.

FIG. 9P shows the assembly comprised of the material engagement elementsin the perpendicular state, the temporary stabilizing material, theflexible base material, and the spherical mold.

FIG. 9Q shows assembly comprised of the material engagement elements inthe perpendicular state, the temporary stabilizing material, and theflexible base material being removed and inverted from the sphericalmold.

FIG. 9R shows the assembly comprised of the material engagement elementsin the perpendicular state, the temporary stabilizing material, and theflexible base material.

FIG. 9S is a hidden lines shown view of FIG. 9R showing the materialengagement elements in a perpendicular state.

FIG. 9T shows the assembly from FIG. 9S after the temporary stabilizingmaterial had been removed thus leaving the spherical material engagementelement device.

FIG. 9U is a hidden lines view of FIG. 9T the spherical materialengagement element device.

FIG. 9V is an enlarged view of FIG. 9T.

FIG. 10A is a perspective view of a deployable material engagementelement.

FIGS. 10B-10H depict the deployment and removal sequence for thedeployable material engagement element.

FIGS. 11A and 11B depict a material engagement element pad device withskin graft material replacing the flexible base material.

FIGS. 12A-12C depict a material engagement element pad deviceconfiguration used as an adhesive for a conventional bandage.

DETAILED DESCRIPTION

Example embodiments described herein are directed to an array ofengagement elements. Such engagement elements may be produced such thatthey are arranged within a substantially flat sheet of material, thuscreating an engagement element patterned sheet. The sheet material maybe comprised of a single layer of shape memory alloy or shape memorypolymer, multiple layers of shape memory alloys and/or shape memorypolymers with distinguishable activation parameters, or any othersuitable material or materials. The engagement elements may besubsequently processed and configured such that they are substantiallyperpendicular to the surface of the engagement element patterned sheet.The engagement element patterned sheet can then be processed such thatthe distal and proximal ends of the engagement elements are containedwithin two separate sections of material or materials, a temporarystabilizing material and a flexible base material respectively. For someembodiments, this process may be a two step mold process. The temporarystabilizing material which incorporates the distal ends of theengagement elements can then be removed prior to the deployment and/oractivation of the engagement device. The flexible base material whichincorporates the proximal ends of the engagement elements remains withthe given apparatus. The pattern of the substantially flat engagementelement array may be suitably configured for any engagement deviceconfiguration. Therefore, this process may be used in order to create avariety of apparatus, including a flat pad, a cylindrically symmetrictube, a cylindrically symmetric balloon, a spherically symmetricballoon, as well as other configurations of engagement devices. Anembodiment of an engagement element configuration wherein the engagementelement lies in close proximity to the surface of the flexible basematerial prior to the deployment of the engagement device is disclosedherein. Embodiments of engagement devices wherein the flexible basematerial is comprised of skin graft material are disclosed herein.Embodiments wherein a suitable configuration of engagement elements andflexible base material are applied as an adhesive to the surface of aconventional bandage are disclosed herein.

Some embodiments herein describe methods by which the device embodimentsdescribed in U.S. application Ser. No. 13/583,199, and U.S. applicationSer. No. 13/119,540, now U.S. Pat. No. 8,906,046, may be manufactured.The nomenclature engagement elements used within this document refers toembodiments that can have the same features, dimensions, and materialsas embodiments in the documents incorporated by reference referred to asthe following: microposts, shape memory microposts, tissue engagementmembers, tissue engagement elements, shape memory engagement elements,and tissue capture elements. The nomenclature flexible base materialused in this document refers to embodiments that can have with the samefeatures, dimensions, and materials as embodiments in the documentsincorporated by reference referred to as the following: flexiblematerial and substrate material. The methods discussed herein may beused to manufacture any suitable configuration of engagement devicesincluding an material engagement element pad 78 as shown in FIG. 6D,cylindrical material engagement element devices 104 and 105 as shown inFIGS. 7P and 7Q respectively, a spherical material engagement elementdevice 152 as shown in FIG. 9T, or any other suitable materialengagement element device configuration. For some indications which mayor may not include medical applications, it can be desirable to scalethe engagement elements up such that any suitable devices whichincorporate them may be used for purposes of adhesion. The process ofadhesion through the use of deployment and activation of engagementelements may also have applications in industry wherein any penetrablematerial such as rubber, silicone, foam, gauze, or any other suitablematerial may be adhered to with the use of this technology.

In PCT/US09/57348 FIG. 7A and paragraph 69 describe a pad comprised offlexible base material and an array of engagement elements, aconfiguration which will hereto be referred to as a material engagementelement pad. The methods discussed herein detail the manufacture of amaterial engagement element pad. FIG. 1A shows sheet material 10 with apattern of material engagement element slots 14 being cut into the sheetmaterial 10 by a laser beam 12. The sheet material 10 may be comprisedof any suitable single layer of material or any suitable combination ofmultiple layers of suitable materials. For example the sheet material 10may be comprised of a single layer of shape memory alloy material or asingle layer of shape memory polymer material. It may also be desirablefor the sheet material 10 to be comprised of multiple layers of anysuitable materials that have been suitably processed. For example, theshape memory polymer composite sheet capable of multiple deflections asdescribed in PCT/US11/02802 FIGS. 7A-7E and paragraph 34. The shapememory materials described in this document may be activated by any ofthe following activation methods: thermal activation, activation by theapplication of ultra violet (UV) radiation, activation by surroundingmedium PH change, activation by the application of a magnetic field,activation by the application of electric current, activation by theapplication of radio frequency (RF) energy, or any other suitable shapememory material activation method.

FIG. 1B is a perspective view of a completed material engagement elementsheet 16 after the cutting process. The material engagement elementsheet 16 is comprised of the sheet material 10 and the materialengagement element slots 14. The method to cut the material engagementelement slots 14 for the described embodiments is laser cutting; howeverany of the following methods could also be used: waterjet cutting,microstamping, nanostamping, chemical etching, or photochemical etching.Dimension 11, the thickness of the sheet material 10 is also shown inFIG. 1B. FIG. 1C is a close up view of the front surface of the materialengagement element sheet 16 which provides a detailed view of thematerial engagement element slots 14. Material engagement elements 20extend from the sides 21 a, 21 b of the material engagement elementslots 14 with a gap 22 between the sheet material 10 and the materialengagement elements 20. A material engagement element sheet locationhole 18 is provided for alignment of the material engagement elementsheet 16 during processing. Also shown in FIG. 1C are the followingdimensions: dimension 24 is the width dimension W of the materialengagement element slot 14, dimension 25 is the width dimension of thesheet material 10 between the material engagement element slots 14, anddimension 26 is the distance between subsequent material engagementelements 20 contained within the material engagement element slots 14.Dimension 11 the thickness of the sheet material 10 is hereto labeledwith the parameter t. The parameter t will be used in order to setranges on the other dimensions. The thickness t (dimension 11) of thesheet material 10 can vary from 1 micron to 1 millimeter. Dimension 24the width dimension of the material engagement element slot 14 can rangefrom 10*t to 100*t. Once dimension 24 is chosen, dimension 25 can rangefrom 1/10*(dimension 24) to 2*(dimension 24). The distance betweensubsequent material engagement elements can range from 1/10*(dimension24) to 2*(dimension 24).

The gap 22 between the sheet material 10 and the material engagementelements 20 and the fact that the material engagement elements 20 remainattached to the sheet material 10 after the cutting process are twosignificant improvements to this embodiment over previous embodiments ofmaterial engagement elements cut from sheet material. As an example,consider the material engagement elements shown in FIG. 9A ofPCT/US11/02802; each material engagement element is cut from the sheetmaterial and then has to be individually processed: fixed into theflexible base material and then molded. For the embodiment currentlybeing described, as shown in FIG. 1C, each material engagement element20 remains attached to the sheet material 10 after the cutting processand the gap 22 isolates each material engagement element 20 from thesurrounding sheet material 10. Because the material engagement elements20 remain attached to the sheet material 10 and are isolated from thesheet material 10 by the gap 22, all of the material engagement elements20 attached to the material engagement element sheet 16 may be processedsimultaneously as opposed to individually. FIG. 1D depicts the profileof a typical material engagement element embodiment 20. The materialengagement element 20 tapers to a distal end 30 which provides asharpened tissue penetrating tip. Dimension 28 is the length of thematerial engagement element 20. Dimension 28 can range from ½*(dimension 24) to 1*(dimension 24) where dimension 24 is the dimensionof the width W of the material engagement element slot 14. The materialengagement element 20 includes two flanges 34, the dimensions of whichare represented by dimension 36. Dimension 36 may be 1 to 2× thedimension 38 of the width of the base of the material engagement element20. Dimension 38 can range from 4*t to 10*t where t is the thickness ofthe sheet material 10. The flange 34 incorporates flat surface 40, whichwhen potted into the flexible base material 76, prevents the materialengagement element 20 from tearing out of the flexible base material 76.

For some embodiments of the sheet material 10 it may be desirable to setan engagement shape into the material engagement elements 20. Thematerial engagement elements 20 can then be flattened in order tocontinue with processing. The shape setting/flattening process would notbe necessary for sheet material 10 embodiments that rely on pre-strainedsheets in order to achieve an engagement state; as an example of thepre-strained sheet deflection process see PCT/US11/02802 FIGS. 7A-7E andparagraph 34. Sheet material 10 embodiments that might require the shapesetting/flattening process would include a single layer of shape memoryalloy such as Nitinol. In this case an “engagement” shape may be setinto the Nitonol material with the application of an appropriate thermalcycle. For example, the sheet material 10 may be confined to the desiredengagement shape and then heated to a given temperature (e.g. 500° C.)for a given duration (e.g. 10 minutes). This process will set theengagement shape into the shape memory alloy material. When the materialis below its transition temperature (Af temperature) it is malleable(Martensite phase) and when it above its transition temperature(Austenite phase) it reverts to the engagement shape. For the case ofthe material engagement element sheet 16 with sheet material 10comprised of a single layer of shape memory alloy, it may be desirableto shape set radii into the material engagement elements 20. The shapeset radius is the means by which a shape memory alloy materialengagement element 20 may assume an engagement state and capture tissueonce it is deployed as shown in PCT/US09/57348 FIGS. 2A-2D.

FIG. 2A depicts a bottom radius fixture 42. The bottom radius fixture 42incorporates a pattern of positive radii bosses 44, the profiles ofwhich conform to the desired radii to be set into the materialengagement elements 20. FIG. 2B shows the material engagement elementsheet 16 placed onto the bottom radius fixture 42. The materialengagement element sheet location holes 18 are located such that placingthe material engagement element sheet 16 over guiding posts on thebottom radius fixture 42 aligns the material engagement element slots 14with the positive radii bosses 44. FIG. 2C shows a cut away view of thetop radius fixture 46 placed into position over the bottom radiusfixture 42. The top radius fixture 46 incorporates a pattern of radiusslots 48, the profiles of which conform to the desired radii to be setinto the material engagement elements 20. FIG. 2D shows a cut away viewof the bottom radius fixture 42, the top radius fixture 48, the radiusslot 48, a positive radius boss 44, and an individual materialengagement element 20. Section A-A in FIG. 2D is through the materialengagement element 20, and FIG. 2E shows the orientation of the materialengagement element 20 with respect to the bottom radius fixture 42 andtop radius fixture 46. As seen in FIG. 2D, the radius dimension 49(labeled in this text as r1) that defines the profile of the radius slot48 may be within the range r1=W/(2*I) to r1=W/π, where W is the widthdimension 24 of the material engagement element slot 14. Also shown inFIG. 2D is the radius dimension 47 (labeled in this text as r2) whichdefines the profile of the positive radius boss 44. The radius r2 isdefined by the equation r2=r1-t where r1 is the radius of the radiusslot 48, and t is the thickness of the sheet material 10. The center ofr2 is offset from the surface if the bottom radius fixture 42 by thedistance t as shown in FIG. 2D. FIG. 2F shows an applied force 50squeezing the top radius fixture 46 into the bottom radius fixture 42thus forcing the material engagement element 20 to begin to conform tothe profiles of the radius slot 48 and the positive radius boss 44. FIG.2G shows the top radius fixture 46 completely deployed onto the bottomradius fixture 42 thus confining the material engagement element 20 toits engagement state 20′ as shown in FIG. 2H. FIG. 2I shows a close upview of FIG. 2C with the top radius fixture 46, the bottom radiusfixture 42, and the material engagement elements in their engagementstate 20′. FIG. 2J shows the material engagement element sheet (elementsin engagement state) 16′, and the material engagement elements inengagement state 20′. When confined as shown in FIGS. 2C, 2G, and 2I thematerial engagement element sheet 16 may be shape set with a temperaturecycle appropriate to the material. After the engagement shape has beenset into the material engagement elements 20′, it may be desirable toreshape them back into a flat state before any subsequent processing isperformed.

FIG. 3A is a perspective view of the material engagement element sheet(elements in engagement state) 16′ and two flat plate fixtures 52. FIG.3B shows the two flat plate fixtures 52 forced into contact with thematerial engagement element sheet (elements in engagement state) 16′ byan applied force 50 a thus forcing the material engagement elements inengagement state 20′ into material engagement elements in a flat state20. FIG. 3C shows the flat plate fixtures 52 being removed and theresulting material engagement element sheet 16. FIG. 3D is a close upview of FIG. 3C showing the flat plate fixtures 52, the materialengagement element sheet 16, and the material engagement elements 20 ina flattened state.

The methods discussed henceforth to complete the manufacturing of thematerial engagement element pad apply to all embodiments of the sheetmaterial 10. The material engagement elements 20 can now be manipulatedsuch that they are in a state that is substantially perpendicular to thesurface of the sheet material 10. FIG. 4A is a perspective view of abottom perpendicular fixture 54 which incorporates a pattern of positiveperpendicular bosses 56. FIG. 4B shows the material engagement elementsheet 16 placed onto the bottom perpendicular fixture 54. The materialengagement element sheet location holes 18 are located such that placingthe material engagement element sheet 16 over guiding posts on thebottom perpendicular fixture 54 aligns the material engagement elementslots 14 with the positive perpendicular bosses 56. The positiveperpendicular bosses 56 provide a surface whose profile is perpendicularto the surface of the sheet material 10. FIG. 4C shows a cut away viewof the top perpendicular fixture 58 placed into position over the bottomperpendicular fixture 54. FIG. 4D shows a cut away view of the bottomperpendicular fixture 54, the top perpendicular fixture 58, theperpendicular slot 60, a positive perpendicular boss 56, an appliedforce 50 b, and an individual material engagement element 20. The topperpendicular fixture 58 incorporates perpendicular slots 60 the profileof which incorporate a surface 59 that is perpendicular to the surfaceof the sheet material 10. For purposes of clarity, the materialengagement element sheet 16 is hidden and only the individual materialengagement element 20 is shown. FIG. 4D shows the applied force 50 bsqueezing the top perpendicular fixture 58 towards the bottomperpendicular fixture 54. FIG. 4E shows the top perpendicular fixture58, the bottom perpendicular fixture 54, and the material engagementelement 20 forced into a perpendicular state 20″ by the application ofthe force to the fixtures. As shown in FIG. 4E, the gap between theperpendicular slots 60 and the positive perpendicular bosses 56 is thethickness t of the sheet material 10. Only a single material engagementelement 20 is shown extending from one side of the slot in the materialengagement element sheet. Alternating elements from the opposite side ofthe slot are received in the opposing side of the gap between theperpendicular slots 60 and positive perpendicular bosses 56. FIG. 4Fshows a close up view of FIG. 4C with the top perpendicular fixture 58,the bottom perpendicular fixture 54, and the material engagementelements in their perpendicular state 20″. FIG. 4G shows the materialengagement element sheet (elements in engagement state) 16″, the surface61 of the sheet material 10, the material engagement elements inperpendicular state 20″, and surface 61 the front of the sheet material10.

For certain example embodiments of the material engagement element padit is desirable to integrate a flexible base material 76 around thematerial engagement element proximal ends 32, while leaving the materialengagement element distal ends 30 free from flexible base material 76.The use of a temporary stabilizing material 66 is one method by whichthis may be accomplished. FIG. 5A is a perspective view of a bottom moldfixture 62. The bottom mold fixture 62 incorporates the temporarystabilizing material cavity 64. FIG. 5B depicts the temporarystabilizing material cavity 64 partially filled with temporarystabilizing material 66. There is a gap between the upper surface 68 ofthe temporary stabilizing material 66 and the upper surface of thetemporary stabilizing material cavity 70. The temporary stabilizingmaterial 66 may be comprised of any penetrable material such as apolymer, a rubber, a foam, a gauze, or any other suitable material. Thetemporary stabilizing material may be a solid material, or a liquidmaterial that cures into a solid. For some embodiments it may bedesirable to have a the temporary stabilizing material 66 comprised of aliquid that cures into a solid at room temperature such as a roomtemperature vulcanization (RTV) silicone, or an RTV urethane. FIG. 5C isa perspective view of the temporary stabilizing material 66 with thebottom mold fixture 62 hidden. FIG. 5D is a perspective view of thebottom mold fixture 62, the material engagement element sheet (elementsin perpendicular state) 16″, and the temporary stabilizing material 66.The surface 61 of the material engagement element sheet (elements inperpendicular state) 16″ and the upper surface of the temporarystabilizing material cavity 70 are coincident in the figure. FIG. 5E thesame view as FIG. 5D showing the material engagement element sheet(elements in perpendicular state) 16″ and the temporary stabilizingmaterial 66 with the bottom mold fixture 62 hidden. As may be seen inFIG. 5E, the material engagement elements in perpendicular state 20″ arepartially deployed onto the temporary stabilizing material 66. FIG. 5Fis a close up view FIG. 5E showing the material engagement elements inperpendicular state 20″ and the temporary stabilizing material 66. Thegap between the upper surface 68 of the temporary stabilizing material66 and the upper surface of the temporary stabilizing material cavity 70results in the partial deployment of the material engagement elements inperpendicular state 20″ into the temporary stabilizing material 66. Thisleaves the material engagement element proximal ends 32, and thematerial engagement element flanges 34 outside of the temporarystabilizing material 66, while the material engagement element distalends 30 are encapsulated in the temporary stabilizing material 66. Alsoshown in FIG. 5F is a barrier material 71 applied to surface 68 of thetemporary stabilizing material 66. The barrier material 71 prevents thebonding of any material applied to surface 68 of the temporarystabilizing material 66. The barrier material 71 may be a spray onmaterial such as mold release or a Teflon coating, or the barriermaterial 71 could be a bond resistant sheet material such as Teflonsheet. FIG. 5H shows a cut-away of the top mold fixture 72 in place overthe bottom mold fixture 62, the top mold fixture mold cavity 74, thematerial engagement element sheet (elements in perpendicular state) 16″,the top mold fixture mold cavity filled with flexible base material 76,and the barrier material 71. The flexible base material 76 may be anymaterial that cures from a liquid state to a solid state such assilicone, a two part urethane, a curable foam, or any other suitablematerial. FIG. 5I is a perspective view of an embodiment showing thematerial engagement element sheet with elements perpendicular 16″, thetemporary stabilizing material 66, the flexible base material 76, andthe sheet material 10 which remains beyond the temporary stabilizingmaterial 66 and the flexible base material 76 once the embodiment hasbeen removed from bottom mold fixture 62 and the top mold fixture 72.FIG. 5J is a close up hidden lines shown view of the embodiment of FIG.5I showing the stabilizing material 66, the flexible base material 76,the barrier material 71, the material engagement element sheet withelements perpendicular 16″, the material engagement elements inperpendicular state 20″, and the sheet material 10 which remains beyondthe temporary stabilizing material 66 and the flexible base material 76.As can be seen in the figure, the flexible base material 76 encompassesthe material engagement element proximal ends 32 and the materialengagement element flanges 34 thus mechanically fixing the materialengagement elements in perpendicular state 20″ into the flexible basematerial 76.

FIG. 6A is a perspective view of the embodiment of FIGS. 5I and 5Jshowing the temporary stabilizing material 66, the flexible basematerial 76, and the sheet material 10 which remained beyond thetemporary stabilizing material 66 and the flexible base material 76trimmed off such that the sheet material 10 is flush with the profilesof the temporary stabilizing material 66 and the flexible base material76. FIG. 6B is a perspective view of the temporary stabilizing material66 being removed from the material engagement pad element assembly 78through an applied force 50 c. The barrier material 71 prevents thetemporary stabilizing material 66 from adhering to the flexible basematerial 78. FIG. 6C is another view of FIG. 6B, showing the temporarystabilizing material 66 being removed from the engagement pad assemblyby an applied force 50 c. The temporary stabilizing material 66 would beremoved just prior to the deployment of the material engagement elementpad assembly 78. FIG. 6D is a perspective view of the engagement padassembly 78 including the flexible base material 76 and the materialengagement elements in perpendicular state 20″.

In PCT/US09/57348 FIG. 9A and paragraph 72 describe a cylindrical tubecomprised of flexible base material and an array of engagement elements,a configuration which will hereto be referred to as a cylindricalmaterial engagement element device. The methods discussed herein detailthe manufacture of a cylindrical material engagement element device.FIG. 7A shows an embodiment including the material engagement elementsheet (elements perpendicular) 16″, and the temporary stabilizingmaterial 66. This embodiment is equivalent to the configuration shown inFIG. 5E, and the embodiment shown in FIG. 7A has been processed as shownin FIGS. 1A-5D in a manner equivalent to the processing of theembodiment shown in FIG. 5E. FIG. 7B is a close up hidden lines visibleview of the embodiment in FIG. 7A showing the temporary stabilizingmaterial 66, and the material engagement element sheet (elementsperpendicular) 16″. As is made clear by the figure, the materialengagement element distal ends 30 are embedded in the temporarystabilizing material 66 while the material engagement element proximalends 32 remain free of the temporary stabilizing material 66. FIG. 7Cshows the embodiment of FIGS. 7A and 7B: the temporary stabilizingmaterial 66 and the material engagement element sheet (elementsperpendicular) 16″, and a cylindrical mandrel 80 the surface of which iscovered with a temporary adhesive 82. FIG. 7C shows applied force lines50 d which indicate the directions of force applied to the embodimentshown in FIGS. 7A and 7B in order to conform the surface 84 of thetemporary stabilizing material 66 to the surface 86 of the cylindricalmandrel 80. FIG. 7D shows the embodiment from FIGS. 7A and 7B with thesurface 84 of the temporary stabilizing material 66 coincident with thesurface 86 of the cylindrical mandrel 80. Surface 84 and surface 86 areheld together by the temporary adhesive 82. The temporary adhesive 82may be any weak adhesive such as a pressure sensitive adhesive. In yetanother embodiment of the temporary adhesive 82, surface 84 and surface86 may be held together by a mechanical means such as a vacuum. Alsoshown in FIG. 7D is the sheet material 10 which is outside of thematerial engagement element slots 14. FIG. 7E shows the embodiment ofFIG. 7D with the sheet material 10 which was outside of the materialengagement element slots 14 removed leaving the material engagementelement proximal ends 32 exposed. The removal of the sheet material 10which was outside of the engagement element patterned slots 14 may beaccomplished through laser cutting, mechanical cutting, or any othersuitable cutting method. FIG. 7F is a cross section view of theembodiment shown in FIG. 7E showing the material engagement elements inperpendicular state 20″, the temporary stabilizing material 66, and thecylindrical mandrel 80. The material engagement element distal ends 30point toward the cylindrical mandrel axis 88, and the materialengagement element proximal ends 32 remain exposed. In thisconfiguration the material engagement element proximal ends 32 may beencapsulated in flexible base material 76 in a manner such that theflexible base material 76 is contiguous. FIG. 7G shows the bottomcylindrical mold 90 and the bottom cylindrical mold cavity 92. FIG. 7Hshows the embodiment from FIGS. 7E and 7F having the elements inperpendicular state 20″, the temporary stabilizing material 66, and thecylindrical mandrel 80 inserted into the bottom cylindrical mold cavity92 of the bottom cylindrical mold 90. FIG. 7I is identical to FIG. 7Hwith exception of the addition of the top cylindrical mold (shown in cutaway view), which incorporates the top cylindrical mold cavity 96. Also,barrier material 71 has been applied to the surface of the temporarystabilizing material 66. FIG. 7J is identical to FIG. 7I with theexception that flexible base material 76 has been molded onto the bottomcylindrical mold cavity 92 and the top cylindrical mold cavity 96. Theflexible base material 76 encapsulates the material engagement elementproximal ends 32 in a contiguous manner as it is molded. FIG. 7K showsthe embodiment for a cylindrical material engagement element deviceincluding the flexible base material 76, the temporary stabilizingmaterial 66, the cylindrical mandrel 80, and (hidden from view) thematerial engagement elements in a perpendicular state 20″. Theembodiment shown in FIG. 7K has been removed from the bottom cylindricalmold 90 and the top cylindrical mold 94. FIG. 7L shows the embodiment ofFIG. 7K with applied forces 50 e being used in order to peel thecylindrical material engagement element device having the flexible basematerial 76, the temporary stabilizing material 66, and (hidden fromview) the material engagement elements in perpendicular state 20″ off ofthe cylindrical mandrel 80. FIG. 7M is FIG. 7L from a differentperspective. FIG. 7M shows that as the cylindrical material engagementelement device having flexible base material 76, the temporarystabilizing material 66, and the material engagement elements inperpendicular state 20′ (hidden from view) is peeled off of thecylindrical mandrel 80, the cylindrical material engagement elementdevice is inverted. As shown in FIG. 7M, as the embodiment is peeled offthe order of the materials with regard to their distance from thecylindrical axis 88 is reversed. In the section 98 which has not beenpeeled, the temporary stabilizing material 66 is closest to thecylindrical axis 88 and the flexible base material 76 is farthest fromcylindrical axis 88. In the peeled section 100, the order is invertedthat is to say that the flexible base material 76 is closest to thecylindrical axis 88, and temporary stabilizing material 66 is thefarthest from the cylindrical axis 88. FIG. 7N shows the cylindricalmaterial engagement element device having the temporary stabilizingmaterial 66, the flexible base material 76, and (hidden from view) theelements in perpendicular state 20″ after it has been peeled off of thecylindrical mandrel 88 and inverted. FIG. 7O is a hidden lines showncross section of FIG. 7N showing the temporary stabilizing material 66,the flexible base material, and the elements in perpendicular state 20″.When FIG. 7O is compared to FIG. 7F, it may be seen that in FIG. 7O thematerial engagement element distal tips 30 now point away from thecenter of the cylindrical axis formed by the temporary stabilizingmaterial 66 and the flexible base material 76. FIG. 7P is the embodimentof the cylindrical material engagement element device shown in FIG. 7Nafter the temporary stabilizing material 66 has been removed, thisleaving the flexible base material 76 and the engagement elements inperpendicular state 20″. The embodiment shown in FIG. 7P is thecompleted cylindrical material engagement element device 104. FIG. 7Q isyet another embodiment 105 of the cylindrical material engagementelement device wherein the flexible base material 76 is configured as aballoon. The flexible base material 76 incorporates tapered sections103, the forms for which would be incorporated into a cylindricalballoon bottom and top mold assembly. Other than the addition of thetapered sections, the methods used to create the embodiment 105 in FIG.7Q would be identical to those used to create the cylindrical materialengagement element device 104 shown on FIG. 7P.

In PCT/US09/57348 FIG. 8A and paragraph 71 describe a spherical ballooncomprised of flexible base material and an array of engagement elements,a configuration which will hereto be referred to as a spherical materialengagement element device. The methods discussed herein detail themanufacture of a spherical material engagement element device. Globemakers frequently use mathematical devices called gores in order to maptopographical data displayed on a flat surface into date that may bedisplayed onto the surface of a sphere. The mathematical formula for agore is shown below:

$\begin{matrix}{y = {{\pm r}*\tan \frac{\phi}{2}*\sin \frac{x}{r}}} & (1)\end{matrix}$

Where r is the radius of the sphere, φ is the angle of the gore, and xvaries from 0 to ¼ the circumference of the sphere or ½*π*r. FIG. 8Ashows numerical values for x and y in the above gore equation using thefollowing values: sphere diameter=1″ (r=0.5″), and φ=45° which meansthat there a total of 365°/45°=8 gores. FIG. 8A also shows a goreprofile 106, and the profile of a spherical material engagement elementslot 110. As may be seen in FIG. 8A, the upper and lower profiles of thespherical material engagement element slot 110 are created using theirradial distances (radial dimension 109 and radial dimension 107respectively) from the origin [0,0] of the gore profile 106 shown inFIG. 8A. FIG. 8B shows a frontal view of spherical material engagementelement sheet 108 with 8 gore profiles 106 cut using the gore formula(1) and the above parameters. The number of gores in a in a sphericalmaterial engagement element sheet 108 can range from 4 to 12. FIG. 8C isa close up view of FIG. 8B showing the spherical material engagementelement slots 112, the material engagement elements 20, and the sheetmaterial 10. The sheet material 10 may be comprised of a single layer ofshape memory alloy or shape memory polymer, or multiple layers ofpre-strained shape memory alloys and/or shape memory polymers withdistinguishable activation parameters, or any other suitable material ormaterials.

For some embodiments of the sheet material 10 such as a single sheet ofshape memory alloy material, it may be desirable to shape set thematerial engagement elements 20 into material engagement elements inengagement state 20′, and then return the material engagement elementsto a flattened state 20. FIG. 8D depicts a spherical bottom radiusfixture 112. The spherical bottom radius fixture 112 incorporates apattern of spherical positive radii bosses 114, the profiles of whichconform to the desired radii to be set into the material engagementelements 20. FIG. 8E shows the spherical material engagement elementsheet 108 placed onto the spherical bottom radius fixture 112. Thespherical material engagement element slots 112 are aligned with thespherical positive radii bosses 114. FIG. 8F shows a cut away view ofthe spherical top radius fixture 116 placed into position over thespherical bottom radius fixture 112. The spherical top radius fixture116 incorporates a pattern of spherical radius slots 118, the profilesof which conform to the desired radii to be set into the materialengagement elements 20. The spherical radius slots 118 have a profiledefined by a radius r1 (see dimension 49 in FIG. 2D) within the ranger1=W/(2*π) to r1=W/π where W is the width of the spherical materialengagement element slot. The spherical positive boss radii bosses 114have a profile defined by a radius r2 (see dimension 47 in FIG. 2D) theequation for which is r2=r1-t. The spherical top radius fixture 116 isforced down into contact with the spherical bottom radius 112 thusforming radii into the material engagement elements 20 exactly as shownin FIGS. 2D-2G. FIG. 8G is a close up view of the spherical positiveradii bosses 114, the spherical radius slots 118, and the materialengagement elements in the engagement state 20′. FIG. 8H shows thespherical engagement element patterned sheet (elements in engagementstate) 108′, and the engagement elements in engagement state 20′. FIG.8I shows the spherical material engagement element sheet (elements inengagement state) 108′, two flat plate fixtures 52, and an applied force50 f which forces the two flat plate fixtures 52 together as shown inFIG. 8J thus flattening the spherical material engagement element sheet(elements in engagement state) 108′ as shown in FIG. 8K.

The material engagement elements 20 can now be manipulated such thatthey are in a state that is substantially perpendicular to the surfaceof the sheet material 10 of the spherical material engagement elementsheet 108. FIG. 8L is a perspective view of a spherical bottomperpendicular fixture 120 which incorporates spherical positiveperpendicular bosses 122. FIG. 8M shows the spherical materialengagement element sheet 108 placed onto the spherical bottomperpendicular fixture 120. FIG. 8N shows the spherical top perpendicularfixture 124 (which incorporates spherical perpendicular slots 126) beingforced into the spherical bottom perpendicular fixture 120 by an appliedforce 50 g. This forces the material engagement elements 20 intoperpendicular state 20″ exactly as shown in FIGS. 4D and 4E thuscreating the spherical material engagement element sheet (elements inperpendicular state) 108″. The gap between the spherical positiveperpendicular bosses 122 and the spherical perpendicular slots 126 is tthe thickness of the sheet material just as shown in FIG. 4E. FIG. 8O isa close up of FIG. 8N showing the spherical positive perpendicularbosses 122, the spherical perpendicular slots 126, surface 125, and thematerial engagement elements in a perpendicular state 20″.

The spherical material engagement element sheet (elements inperpendicular state) 108″ can now be appropriately inserted into asuitable configuration of temporary stabilizing material 66. FIG. 9A isa perspective view of a spherical flat mold fixture 128 whichincorporates spherical temporary stabilizing material cavities 130. FIG.9B shows the temporary stabilizing material 66 partially filling thespherical temporary stabilizing material cavities 130 of the sphericalflat mold fixture 128. The spherical temporary stabilizing materialcavities 130 are partially filled with the temporary stabilizingmaterial 66, that is there is a gap between the upper surface 132 of thetemporary stabilizing material 66, and the upper surface 134 of thespherical flat mold fixture 128. FIG. 9C shows the spherical materialengagement element sheet (elements in perpendicular state) 108″ insertedinto the temporary stabilizing material 66. Surface 125 (shown in FIG.8O) of the spherical material engagement element sheet (elements inperpendicular state) 108″ is coincident with surface 134 of thespherical flat mold 128. FIG. 9D is a close up view of FIG. 9C showingthe spherical material engagement element slots 114, and the materialengagement elements in perpendicular state 20″ partially inserted intothe temporary stabilizing material 66. FIG. 9E shows the embodimentcomprised of the spherical material engagement element sheet (elementsin perpendicular state) 108″ and the molded temporary stabilizingmaterial 66. FIG. 9F is a view of the rear of the embodiment shown inFIG. 9E comprised of the spherical material engagement element sheet(elements in perpendicular state) 108″ and the molded temporarystabilizing material 66. FIG. 9G shows the embodiment of FIGS. 9E and 9Fwith the sheet material 10 which was outside of the spherical materialengagement slots 110 trimmed off leaving the material engagementelements in a perpendicular state 20″. FIG. 9G also shows a locationhole 135 and the temporary stabilizing material 66. This embodiment willbe referred to as configuration 136. The trimming of the sheet material10 may be accomplished through laser cutting, mechanical cutting, or anyother suitable means. FIG. 9H is a hidden lines view of a spherical mold136 which incorporates the spherical mold base 140 and the location post142. The surface of the spherical mold is covered with temporaryadhesive 82. FIG. 9I shows the embodiment 136 placed over the sphericalmold such that the position hole 135 is concentric with the sphericalmold location post 142. The embodiment 136 is forced onto the uppersurface of the spherical mold 138 by applied forces 50 h. Aconfiguration 136′ identical to embodiment 136 except that the positionhole 135′ is large enough to encompass the spherical mold base 140 issimilarly applied to the lower surface of the spherical mold 140 byapplied forces 50 h. FIG. 9J shows the spherical mold 138, and the upperand lower configurations 136 and 136′ held into place by the temporaryadhesive 82. FIG. 9K is a close up view of the surface of the embodimentshown in FIG. 9J showing the temporary stabilizing material 66, thematerial engagement elements in a perpendicular state 20″, and theexposed material engagement element proximal ends 32. FIG. 9L is ahidden lines shown view if a bottom spherical mold fixture 144 whichincorporates the bottom spherical flexible base material mold cavity146. FIG. 9M shows the embodiment shown in FIG. 9J inserted into thebottom spherical flexible base material mold cavity 146. The embodimentfor forming the spherical material engagement element device shown inFIG. 9J includes the spherical mold 138, and the upper and lowerconfigurations 136 and 136′. FIG. 9N is identical to FIG. 9M with theexception of the addition of the top spherical mold fixture 148 (shownin cut away view) which incorporates the top spherical flexible basematerial mold cavity 150. FIG. 9O shows flexible base material 76 moldedinto the bottom spherical flexible base material mold cavity 146 and thetop spherical flexible base material mold cavity 150 of the bottomspherical mold fixture 144 and the top spherical mold fixture 148. FIG.9P is the spherical material engagement element device with thetemporary stabilizing material 66 (hidden from view in the figure), theflexible base material 76, the material engagement elements in aperpendicular state 20″ (hidden from view in the figure), and thespherical mold 138. FIG. 9Q shows the embodiment of the sphericalmaterial engagement element device with the temporary stabilizingmaterial 66 (hidden from view in the figure), the flexible base material76, and the engagement elements in a perpendicular state 20″ (hiddenfrom view in the figure) being removed from the spherical mold 138 byapplied forces 50 i. As may be seen from the figure, the sphericalmaterial engagement element device with the temporary stabilizingmaterial 66 (hidden from view in the figure), the flexible base material76, and the material engagement elements in a perpendicular state 20″(hidden from view in the figure) is inverted as it is removed from thespherical mold 138. This process is analogous to the removal processdetailed in FIGS. 7L-7N for the cylindrical material engagement elementdevice 104. FIG. 9R shows the embodiment for the spherical materialengagement element device with the temporary stabilizing material 66,the flexible base material 76 (hidden from view in the figure), and thematerial engagement elements in a perpendicular state 20″ (hidden fromview in the figure) after it has been removed from the spherical mold138 and inverted. FIG. 9S is a hidden lines shown view of the embodimentof FIG. 9R showing the temporary stabilizing material 66, the flexiblebase material 76, and the material engagement elements in aperpendicular state 20″. FIG. 9T is the embodiment depicted in FIG. 9Safter the removal of the temporary stabilizing material 66, thus leavingthe spherical material engagement element device 152 which incorporatesflexible base material 76 and material engagement elements in aperpendicular state 20″. FIG. 9U is a hidden lines shown view of FIG.9T. FIG. 9V is a close up view of the surface of the spherical materialengagement element device 152 showing the material engagement elementsin a perpendicular state 20″, and the flexible base material 76. As canbe seen in FIG. 9V, after the inversion process shown in FIG. 9Q theengagement material element distal ends 30 point away from the center ofthe spherical material engagement element device 152. Compare this toFIG. 9K which shows the material engagement element proximal ends 32pointing away from the center of the spherical material engagementelement device 152.

An embodiment of an material engagement element 20 that lies in closecontact to the flexible base material 76 prior to the deployment of thegiven material engagement element device is disclosed hereafter. Thematerial engagement element would assume a “deployment” state once thematerial engagement element device is ready to deploy. This embodimentwould be advantageous when incorporated into material engagement elementdevices which are to be deployed into completely fluid environments. Forexample, a cylindrical material engagement element device 104 which isto be deployed into an artery which contains blood. FIG. 10A shows anembodiment of a deployable material engagement element 154. Thedeployable material engagement element 154 is cut from sheet material 10that is comprised of multiple layers of materials. For example, thesheet material 10 could be comprised of multiple layers of shape memorymaterials with different activation parameters as described inPCT/US11/02802 FIGS. 7A-7E and paragraph 34. FIG. 10B shows a crosssection view of the deployable material engagement element 154. Theelement is comprised of three layers, layer 156, layer 158, and layer160. For this example it is assumed that layers 156 and 160 arepre-stressed shape memory polymers with different activation parameters.Layer 158 may be a shape memory alloy with a body temperature activationshape set in a straight configuration 154 as shown in FIG. 10A. FIG. 10Cshows the deployable engagement element 154 in a state 154′ such that itlies in close proximity to the flexible base material 76. FIG. 10B showsthe deployable material engagement element 154 after the given materialengagement element device had been deployed into a body temperaturefluid environment thus transforming the deployable material engagementelement 154 to its deployment state. The deployable material engagementelement can then be transformed to its engagement state 154″ through theactivation of layer 160 as shown in FIG. 10E. FIG. 10E shows compressionlines 162 which indicate the compression of the material 160 which causethe deflection of the deployable material engagement element to thestate 154 as shown in FIG. 10F. Layer 156 may be activated as shown inFIG. 10G. Compression lines 162 indicate the compression of the material156 thus deforming the deployable material engagement element to thestate 154′″ shown in FIGS. 10G and 10H allowing for the removal of thedeployable material engagement element 154′″.

Embodiments of material engagement element devices wherein the flexiblebase material is comprised of skin graft material are disclosedhereafter. FIG. 11A is a hidden lines shown view of a materialengagement element pad 166 incorporating material engagement elements inthe perpendicular state 20″, and skin graft material 164. The skin graftmaterial 164 may be any of the following: autograft material, allogenicmaterial, or any other suitable skin graft material. The tissue graftmaterial could be cultured around any suitable configuration of materialengagement element sheet with the engagement elements in perpendicularstate 20″. The use of any of these skin graft materials 164 as areplacement for the flexible base material 76 could thus be applied tomaterial engagement element device configurations including thecylindrical material engagement element devices (FIGS. 7P and 7Q), thespherical material engagement element device (FIG. 9T), or any othersuitable material engagement element device configuration.

Embodiments of material engagement element devices wherein the devicesare used as an adhesive for conventional bandages are disclosedhereafter. FIG. 12A shows a perforated material engagement element pad172 being applied to conventional bandage material 170 through the useof an adhesive 168 applied to the surface of the conventional bandagematerial 170. The conventional bandage material may be any of thefollowing: alginate material, collagen material, composite material,contact layer material, foam material, gauze material, binder material,hydrocollodid material, specialty absorptive material, transparent filmmaterial, or any other suitable conventional bandage material. FIG. 12Bshows the perforated material engagement element pad 172 attached to theconventional bandage 170. FIG. 12C is a close up view of FIG. 12Bshowing the conventional bandage material 170, the perforated materialengagement element pad 172, the material engagement elements in aperpendicular state 20″, and holes 174 in the flexible base material 76which allow for the communication of gasses and liquids between thewound site and the conventional bandage 170. The use of any of theconventional bandage materials 170 as a replacement for the flexiblebase material 76 could be applied to any material engagement elementdevice embodiment including the cylindrical material engagement elementdevices (FIGS. 7P and 7Q), the spherical material engagement elementdevice (FIG. 9T), or any other suitable material engagement elementdevice configuration.

What is claimed is:
 1. A method for manufacturing a material engagementelement pad assembly comprising: cutting a pattern of materialengagement element slots and respective material engagement elementsinto a sheet material thereby forming a material engagement elementsheet; forming each material engagement element into a state which isperpendicular to a surface of the sheet material; inserting the materialengagement elements into a temporary stabilizing material such that adistal end of each material engagement element is partially deployedinto the temporary stabilizing material; and forming a flexible basematerial about a proximal end of each material engagement element suchthat the flexible base material encompasses the proximal end of eachmaterial engagement element thereby mechanically fixing each materialengagement element into the flexible base material.
 2. The method ofclaim 1 further comprising shape setting an engagement state into eachmaterial engagement element prior to forming each material engagementelement into a state which is perpendicular to the surface of the sheetmaterial.
 3. The method of claim 2 wherein shape setting an engagementstate into each material engagement element comprises sandwiching thematerial engagement element sheet between a top radius fixture and abottom radius fixture, applying a force to the top radius fixturethereby conforming each material engagement element to profiles of arespective positive radius boss of the bottom radius fixture andrespective radius slot of the top radius fixture, and applying a heattreatment cycle to shape set the material engagement elements into anengagement state.
 4. The method of claim 1 wherein the sheet materialcomprises a composite sheet having two or more layers wherein at leastone layer comprises a pre-strained shape memory material.
 5. The methodof claim 1 wherein forming a flexible base material about a proximal endof each material engagement element further comprises forming theflexible base material about the sheet material.
 6. The method of claim1 wherein forming each material engagement element into a state which isperpendicular to the surface of the sheet material comprises sandwichingthe material engagement element sheet between a top perpendicularfixture and a bottom perpendicular fixture, and applying a force to thetop perpendicular fixture thereby conforming each material engagementelement to surfaces of a respective positive perpendicular boss of thebottom perpendicular fixture and respective perpendicular slot of thetop perpendicular fixture such that each material engagement elementassumes a state perpendicular to the surface of the sheet material.
 7. Amethod for manufacturing a cylindrical material engagement elementdevice comprising: cutting a pattern of material engagement elementslots and respective material engagement elements into a sheet materialthereby forming a material engagement element sheet; forming eachmaterial engagement element into a state which is perpendicular to asurface of the sheet material; inserting the material engagementelements into a temporary stabilizing material such that a distal end ofeach material engagement element is partially deployed into thetemporary stabilizing material; forming the material engagement elementsheet and temporary stabilizing material around a cylindrical mandrel;and forming a flexible base material about a proximal end of eachmaterial engagement element such that the flexible base materialencompasses the proximal end of each material engagement element therebymechanically fixing each material engagement element into the flexiblebase material.
 8. The method of claim 7 further comprising shape settingan engagement state into each material engagement element prior toforming each material engagement element into a state which isperpendicular to the surface of the sheet material.
 9. The method ofclaim 8 wherein shape setting an engagement state into each materialengagement element comprises sandwiching the material engagement elementsheet between a top radius fixture and a bottom radius fixture, applyinga force to the top radius fixture thereby conforming each materialengagement element to profiles of a respective positive radius boss ofthe bottom radius fixture and respective radius slot of the top radiusfixture, and applying a heat treatment cycle to shape set the materialengagement elements into an engagement state.
 10. The method of claim 7wherein the sheet material comprises a composite sheet having two ormore layers wherein at least one layer comprises a pre-strained shapememory material.
 11. The method of claim 7 further comprising trimmingexcess sheet material from the material engagement element sheet priorto forming a flexible base material about a proximal end of eachmaterial engagement element.
 12. The method of claim 7 wherein formingthe material engagement element sheet and temporary stabilizing materialaround the cylindrical mandrel comprises forming the material engagementelement sheet and temporary stabilizing material around the cylindricalmandrel such that the distal end of each material engagement element isdirected toward a cylindrical mandrel axis.
 13. The method of claim 12further comprising removing the cylindrical material engagement elementdevice from the cylindrical mandrel after forming the flexible basematerial about the proximal end of each material engagement element byinverting the cylindrical material engagement element device such thedistal end of each material engagement element is directed away from thecylindrical mandrel axis upon inversion.
 14. A method for manufacturinga spherical material engagement element device comprising: cutting apattern of spherical material engagement element slots and respectivematerial engagement elements into a sheet material thereby forming aspherical material engagement element sheet; forming each materialengagement element into a state which is perpendicular to a surface ofthe sheet material; inserting the material engagement elements into atemporary stabilizing material such that a distal end of each materialengagement element is partially deployed into the temporary stabilizingmaterial; forming the spherical material engagement element sheet andtemporary stabilizing material over the surface of a spherical mold;forming a flexible base material about a proximal end of each materialengagement element such that the flexible base material encompasses theproximal end of each material engagement element thereby mechanicallyfixing each material engagement element into the flexible base material.15. The method of claim 14 further comprising shape setting anengagement state into each material engagement element prior to formingeach material engagement element into a state which is perpendicular tothe surface of the sheet material.
 16. The method of claim 15 whereinshape setting an engagement state into each material engagement elementcomprises sandwiching the spherical material engagement element sheetbetween a spherical top radius fixture and a spherical bottom radiusfixture, applying a force to the spherical top radius fixture therebyconforming each material engagement element to profiles of a respectivespherical positive radius boss of the spherical bottom radius fixtureand respective spherical radius slot of the spherical top radiusfixture, and applying a heat treatment cycle to shape set the materialengagement elements into an engagement state.
 17. The method of claim 14wherein the sheet material comprises a composite sheet having two ormore layers wherein at least one layer comprises a pre-strained shapememory material.
 18. The method of claim 14 further comprising trimmingexcess sheet material from the spherical material engagement elementsheet prior to forming a flexible base material about a proximal end ofeach material engagement element.
 19. The method of claim 14 whereinforming the spherical material engagement element sheet and temporarystabilizing material around the spherical mold comprises forming thespherical material engagement element sheet and temporary stabilizingmaterial around the spherical mold such that the distal end of eachmaterial engagement element is directed toward a center of the sphericalmaterial engagement element device.
 20. The method of claim 19 furthercomprising removing the spherical material engagement element devicefrom the spherical mold after forming the flexible base material aboutthe proximal end of each material engagement element by inverting thespherical material engagement element device such the distal end of eachmaterial engagement element is directed away from the center of thespherical material engagement element device upon inversion.